High temperature heat resistant acrylics

ABSTRACT

A high temperature heat resistant methacrylate-maleimide copolymer having at least 90% by weight methyl methacrylate monomer and up to about 10% by weight maleimide monomer to form a clear, weather-resistant copolymer having glass transition temperatures from about 105 DEG  C. to about 131 DEG  C. and a method of manufacture of the copolymers through an extremely high conversion bulk polymerization process.

BACKGROUND Field of the Invention and Description of Related Art

The present invention relates to high temperature heat resistant acrylicpolymers preferably made through free radical polymerization of methylmethacrylate (MMA) and related acrylates with maleimide (MI) and relatedmaleimides through an extremely high conversion bulk polymerizationprocess to produce extremely pure, improved acrylic copolymers.

The acrylic copolymers of the present invention have approximately thesame physical properties as conventional acrylic polymers except thatthe present invention polymers have high purity, a higher glasstransition temperature, better impact resistance higher heat distortiontemperatures, and in the case of preferred polymers, excellent clarity.

In general, acrylics are well known and have excellent opticalproperties and weatherability for numerous uses such as in lightingfixtures, automobile tail light lenses, dials, video discs, opthalmiccontact lenses and numerous other articles where durable, weatherable,clear features are desired.

In order to obtain specific optimized physical properties for acrylics,it has been known to polymerize different monomers to form copolymers.The art of copolyermization had an early start in polymer technologysince it was found that copolymerization of a mixture of two or moremonomers lead to polymers which had different and/or more suitablephysical properties than either of the homopolymers alone or amechanical blend of polymers formed from the individual monomers.

Poly (methyl methacrylate) (PMMA) is the most popular commercial polymerin the acrylic industry at present. The relatively high clarity andexcellent light transmission of PMMA, i.e., transparency, coupled withits resistance to sunlight and low density make this polymer ideallysuited to production of automobile tail light lenses, dial covers,lighting fixtures and other related articles. PMMA has excellent weatherresistance, durability and is pleasing in appearance when formulatedinto relatively thick sections and these features render PMMA andrelated acrylics ideal for such end uses.

In the context of the present invention the term transparent refers tothe property of the copolymers of the present invention to betransparent to light and specifically refers to the fact that thepreferred copolymers of the present invention have transparencyproperties about the same as the transparency properties of conventionalPMMA.

The heat distortion temperature (HDT) of PMMA copolymers aresatisfactory for most uses for relatively short times at temperatures of90°-102° C. (195°-295° F.). The glass transition temperature (Tg) ofPMMA copolymers are generally between 85°-105° C. However, forrelatively long time periods and/or for lighting systems in whichrelatively great amounts of heat are produced by the lamps, such as, forexample, in mercury vapor lighting systems, the glass transitiontemperatures and heat distortion temperatures of conventional PMMAcopolymers are unsatisfactorily low.

SUMMARY OF THE INVENTION

The above-stated need for a high temperature acrylic has been satisfiedby the present invention which encompasses a copolymer usingmethacrylate and maleimide group monomers. The acrylic copolymers of thepresent invention are manufactured in a specially designed bulkpolymerization process having extremely high conversion rates for themethacrylate and maleimide group monomers. The finalmethacrylate-maleimide group copolymers are transparent without phaseseparation and have superior heat resistance properties compared tocommercial PMMA based on HDT and Tg data. The MMA/MI copolymers of thepresent invention can be made in a wide range of molecular weights andwith a wide range of acrylate group monomers and a wide range ofmaleimide group monomers.

The term phase separation refers to a phenomenon found, especially, inextremely high conversion copolymerization processes, that is, where theconversion rate is about 98% or above. One of the unusual features ofthe preferred copolymers of the present invention is their ability toavoid phase separation at such extremely high conversion rates. The termphase separation refers to the cloudy appearance of a copolymer,currently believed to be caused by light scattering due to the differentrefractive indices of the monomers used in the polymer mixture and thedomain size phenomenon as described in J. Shen, Ph.D dissertationentitled "Microphase Separation in Copolymers from High Conversion FreeRadical Polymerization", The University of Akron, Ohio 44325 (1988).

Methacrylate group monomers (group I), such as methyl methacrylate;ethyl methacrylate, maleimide group monomers (group II), such asmaleimide, N-methylmaleimide, N-ethylmaleimide, N-phenylmaleimide andN-cyclohexylmaleimide; and acrylate group monomers (group III), such asethyl acrylate, butyl acrylate and propyl acrylate, can be mixed as I,II, III or I, II, or II, III mixtures, to provide copolymers with two orthree or more different constituent monomers. In the bulk polymerizationof the present invention, two types of initiators are used. The firstinitiator is a low temperature initiator having a half life ofapproximately 10 hours in the temperature range of 50°-70° C. and thesecond initiator is a high temperature initiator having a half life ofapproximately 10 hours at temperatures between 90°-130° C.

The low temperature initiators can be, for example, lauroyl peroxide,benzoyl peroxide, decanoyl peroxide, isononanoyl peroxide, and propionylperoxide as well as others known to be equivalent to those of ordinaryskill in the acrylic polymer art. The second, or high temperature,initiator can be, for example, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, t-butylperoxy isopropyl carbonate, t-butyl peracetate, t-butylperbenzoate and dicumyl peroxide as well as others known to beequivalent by those of ordinary skill in the acrylic polymer art.

Also, mercaptans are used in the present process for controlling thechain lengths, that is, the molecular weights, of the copolymer.Mercaptans such as n-dodecyl mercaptan, n-butyl mercaptan, t-butylmercaptan and others known in this art may be used in the bulkpolymerization process of the present invention.

Additives such as internal lubricants, external lubricants,UV-absorbers, processing aids, antioxidants, dyes, thermal stabilizersand others additives known to those of ordinary skill in the acrylicpolymer art may be added to the process ingredient mixture depending onthe need and physical properties desired with respect to the end use ofthe particular copolymer.

Preparation of the finished polymer involves thoroughly mixing thechosen monomers, initiators, mercaptans and additives desired. Themixing is conducted in a stainless steel container or tank and mixingcontinues to insure that all ingredients are thoroughly dissolved. Themixture is then purged with nitrogen gas for 20-30 minutes prior tofiltration through a 0.2 micron nylon 66 or Teflon™ filter. A 20+ psivacuum is then applied to the mixture for approximately 20 to 30 minutesto purge remaining gases and then the mixture is transferred to a nylon66 or nylon 6 polymer cell for polymerization. The cell is similar inappearance to a large plastic trash bag and its dimensions are dependentupon the amount of mixture intended to be placed in the bag forpolymerization. The copolymer cell or bag dimensions are chosen toinsure uniform temperature distribution within the block or mix duringthe baking or polymerization step of the manufacturing process. Forexample, a typical thickness of the nylon bag film or wall is about 1-3mils for a bag thickness of no more than 11/4 inches, although otherdimensions may be used in specific processes. The bag dimension and wallthickness of the bag are chosen to and function to provide relativelyhigh surface area on the bag peripheries to maximize removal of theexothermic heat of reaction and thus maintain a low temperature dropbetween the monomer mixture filled bag and the oven temperature during,especially, those periods when the polymerization reaction is takingplace at its fastest rate.

The bulk polymerization process of the present invention uses a constanttemperature reaction chamber, wherein at the beginning of the processheat is added to initiate the reaction, and later during thepolymerization reaction heat is removed to prevent bubble formation inthe reacting mixture, and later additional heat is added to force thereaction to extremely high conversion rates.

Typically, the temperatures within the reaction chamber is controlled bysupplying heat to the chamber at various times during the polymerizationprocess, and supplying cooling to the chamber at other times during thepolymerization process. Also, the time-temperature profile for a givenpolymerization process is controlled through a microprocessor system.Initially heat is supplied to the reaction chamber to help initiate thepolymerization reaction. As the polymerization reaction proceeds excessheat is produced during various stages of the polymerization reaction.In those excess heat production stages the reaction chamber heaters arede-energized and the reaction chamber cooling system is energized toblow cool air over the mixture containing cells to control thetemperatures to within about 0.5° C. of the desired temperature. It hasbeen found that a typical time-temperature program for polymerizingcopolymers of the present invention within the reaction chamber is asfollows:

    ______________________________________                                        Step         Temperature                                                                              Time                                                  ______________________________________                                        1            63° C.                                                                            8 hours                                               2            55° C.                                                                            3 hours                                               3            75° C.                                                                            2 hours                                               4            115° C.                                                                           4 hours                                               5            135° C.                                                                           6 hours                                               ______________________________________                                    

In such a typical polymerization process, during the first 8 hours theaddition of heat to the reaction chamber is required and during thesecond step removal of heat from the reaction chamber is required.During the last three steps the addition of heat to the reaction chamberis also required. This later heat addition functions to push thereaction to high, and in the case of the fifth step, to push thereaction to extremely high conversion. Although the time-temperatureprofile of the polymerization reaction may be modified for a givenmixture, the time-temperature perimeters should be adjusted so that thepolymerization takes place at a rate not so fast that bubbles, hot spotsor distortions are formed in the polymerizing mixture, and so that inlater stages of the polymerization sufficient heat is added to themixture to achieve extremely high conversion, that is, conversion inexcess of 98%.

The final, bulk polymers produced have a very smooth appearance and noirregular, or "hot spot" surfaces. They also exhibit glass transitiontemperatures of approximately 105° C. to 131° C. with increasingfraction of MI content. These are superior glass transition temperaturescompared to glass transition temperatures of approximately 85°-105° C.for conventional PMMA copolymers.

The final copolymers of the present invention generally comprise 90% ormore of MMA fraction and up to about 10% MI fraction of the monomermixture in the copolymer.

The low value of maleimide composition in copolymers of the presentinvention is based on the fact that approximately 11% by weightmaleimide may be dissolved in methyl methacrylate at room temperatures.Should mixing take place at higher temperatures, the relativeproportions of methacrylate and maleimide monomers can be adjusted. Thevalue of MI composition is a function of solubility of the particularmaleimide chosen in the particular methacrylate or acrylate chosen.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of the bulk polymerization process of thepresent invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

By reference to FIG. 1 and the figures in the tables discussed hereinpreferred embodiments of the present invention will be described.

The starting materials for the copolymers of the present inventioninclude monomers, high and low temperature initators, chain transferagents, and optional additives such as lubricants, UV-absorbers, etc.

The acrylic copolymers of the present invention include two or threemonomer component acrylic polymers. The first monomer typically is amethacrylate monomer such as methyl methacrylate or ethyl methacrylate.The second monomer is a maleimide monomer such as maleimide,N-methylmaleimide, N-ethylmaleimide, N-phenyl-maleimide orN-cyclohexylmaleimide. The third monomer is an acrylic monomer, such asethyl acrylate, butyl acrylate or propyl acrylate.

The first, second and third monomers may be mixed in combinations ofeither first, second and third, or first and second, or second and thirdto form the basic monomer mixture. This mixture is used in preparing aspecific acrylic polymer of the present invention.

The preferred maleimides of the present invention are set forth,together with their structural formula, below: ##STR1##

The preferred methacrylate of the present invention is methylmethacrylate, whose structural formula is shown below: ##STR2##

Conventional poly (methyl methacrylate) (PMMA) is also shown below:##STR3##

Two types of initiators are also used in the polymerization process ofthe present invention. The first initiator is a low temperatureinitiator having a half life of about 10 hours at temperatures between50°-70° C./ and the second initiator is a high temperature initiatorhaving a half life of 10 hours between temperatures of 90°-130° C. Thelow temperature initiator may be, for example, lauroyl peroxide, benzoylperoxide, decanoyl peroxide, isononanoyl peroxide, propionyl peroxide orother low temperature initiators known in the acrylic polymer arts. Thehigh temperature initiator may be, for example, 2,5-dimethyl-2,5di(t-butylperoxy) hexane, t-butylperoxy isopropyl carbonate, t-butylperacetate, t-butyl perbenzoate, dicumyl peroxide and other hightemperature initiators known in the acrylic polymer arts.

In order to control the chain length or the molecular weights of thespecific polymer, chain length controlling additives must be used.Preferably mercaptans, such as n-dodecyl mercaptan, n-butyl mercaptan,t-butyl mercaptan and others known to be equivalent to those in theacrylic polymer art may be used.

Finally, other additives, well known in the acrylic polymer arts, suchas internal lubricants, external lubricants, UV-absorbers, processingaids, antioxidants, dyes, thermal stabilizers and so forth may be addedto the ingredient mixture depending on the properties desired for thefinal acrylic polymer.

Referring to the FIG. 1 block diagram, the bulk polymerization processof the present invention will be described. The physical components ofthe bulk polymerization process shown in FIG. 1 are all conventionalcomponents and are presently used to make conventional PMMA copolymers.The system, however, will be described herein to aid in understandingthe process and copolymers of the present invention.

The bulk polymerization system 1 has a feed funnel 2 for introduction ofthe raw material mixture including the monomers, initiators, chaintransfer agents, and additives. The mixture is fed through funnel 2 to aconventional compounding tank 3 where the ingredients are thoroughlymixed. The mixed ingredients are then passed through a 0.2 micron filter4 which is made of, preferably nylon 66 or Teflon™ to remove essentiallyall undissolved impurities having a diameter greater than 0.2 microns.The preferred filter is sold under the tradename ULTIPOR N₆₆ by PallPuerto Rico, Inc., Fajardo, Puerto Rico, USA 00648. The filtered rawmaterial mixture is then fed to a vacuum tank 5. Vacuum pump 6 draws avacuum on the tank 5 for approximately 20-30 minutes to establish andmaintain a vacuum of 20+ psi to draw off oxygen, air and other gaseousimpurities that may be found in the mixture. After vacuum treatment themixture is then placed in a plurality of bags 7, also known as cells 7.The cells or bags 7 are preferably made of nylon 66 film and areselected in size of the cell and thickness of the cell wall or film soas to provide relatively high surface area for the mixture containedwithin the bag and to provide a clean container in which thepolymerization reaction takes place. Preferably the thickness of thefilled bag should be less than 11/4 inches after a particular bag hasbeen filled with mixture from the tank 5. The thickness of the nylon 66cell wall is preferably 1-3 mils in thickness. The plurality of bags arethen placed on racks or trays and placed into a large reaction chamber8, which at various times functions as either an oven, or as a coolingchamber and in which a batch of mixture filled bags 7 is polymerized.The dimensions of the bags 7, the racks in which the bags are held, andthe reaction chamber 8 have been designed to provide relatively highsurface area of the bags. The bags 7 are exposed to the ambienttemperature within the reaction chamber 8 and the temperatures of thepolymerizing mixture within each bag are kept very near to the ambienttemperature within the reaction chamber 8 during either heating orcooling. The reaction chamber 8 is provided with a conventional heatingsystem 9, a conventional cooling system 10, and a conventionaltemperature control system 11 for establishing and maintaining a desiredtemperature at desired times within the reaction chamber 8. Thetemperature control system 11 is a conventional microprocessor controlsystem which maintains a deviation of + or -0.5° C. from a programmedtemperature.

During polymerization of the mixture within the reaction chamber 8,various temperature-time conditions will provide usable, preferable, oroptimum high temperature heat resistant acrylic polymers of the presentinvention. Below are listed in Table I, Table II and Table III theusable, preferred and optimum time-temperature conditions for theacrylic polymers of the present invention.

                  TABLE I                                                         ______________________________________                                        Usable Time-Temperature Conditions                                            Step      Temperature                                                                              Time                                                     ______________________________________                                        1         55-70° C.                                                                         5-10 hours                                               2         40-55° C.                                                                         5-10 hours                                               3         70-85° C.                                                                         5-10 hours                                               4         100-120° C.                                                                       Greater than 3 hours                                     5         120-250° C.                                                                       Greater than 3 hours                                     ______________________________________                                    

                  TABLE II                                                        ______________________________________                                        Preferrable Time-Temperature Conditions                                       Step       Temperature                                                                              Time                                                    ______________________________________                                        1          63° ± 2° C.                                                             8 ± 2 hours                                          2          55° ± 5° C.                                                             3 ± 2 hours                                          3          75° ± 5° C.                                                             About 1-3 hours                                         4          115° ± 5° C.                                                            4 ± 1 hour                                           5          135° ± 15° C.                                                           6 ± 1 hour                                           ______________________________________                                    

                  TABLE III                                                       ______________________________________                                        Optimum Time-Temperature Conditions                                           Step         Temperature                                                                              Time                                                  ______________________________________                                        1            63° C.                                                                            8 hours                                               2            55° C.                                                                            3 hours                                               3            75° C.                                                                            2 hours                                               4            115° C.                                                                           4 hours                                               5            135° C.                                                                           6 hours                                               ______________________________________                                    

In regard to the above Tables I-III, when the mixture filled cells 7 areplaced into the reaction chamber 8, heat is added through heating system9 to help initiate the polymerization reaction. Adding heat usuallytakes place during the first step in order to maintain the temperaturewithin the ranges set forth in Tables I-III. Typically, thepolymerization process is proceeding fairly quickly and exothermicallyby the time step 2 is reached and during step 2 the heating system 9 isde-energized and the cooling system 10 is automatically energized toestablish and maintain the temperatures as set forth in the Tables forthe time periods set forth in step 2. During steps 3-5, typically, heatis added to the reaction chamber 8 to push the polymerization reactionto high conversion. For example, typically, step 3 requires the additionof heat to maintain the polymerizing mixture in the bags at the desiredtemperatures for the desired times as set forth in Tables I-III. Also,in step 4, additional heat is required to push the polymerization to ahigh conversion and, regarding step 5, even more additional heat isadded to push the polymerization reaction to extremely high conversion.

In the above-described reaction, it has been found that at least 5 stepsfor the time-temperature profile of the reaction is needed to preventboiling, i.e., bubbling or formation hot spots in the mixture duringpolymerization. Generally, more steps in the reaction are advantageousin terms of minimizing or eliminating bubble formation in thepolymerizing mixture. However, it is also desired to have the minimumnumber of steps in order to conduct the reaction more quickly andsimply. For a typical 5-step process used to make copolymers of thepresent invention, the desired goal of avoidance of bubble formation isachieved.

In accordance with the principles of the present invention, a number ofsamples of copolymers of the present invention were prepared inaccordance with the bulk polymerization process described above. InExamples 1-5, various proportions of methyl methaorylate and maleimidewere used as the group I and II monomers in the copolymer ingredientmix. In all cases in Examples 1-5, lauroyl peroxide was used as the lowtemperature initiator, 2,5-dimethyl-2,5-di(t-butylperoxy) hexane wasused as the high temperature initiator to aid in driving thepolymerization to a high percentage of conversion and n-dodecylmercaptan was used as a chain transfer agent. In Table IV, set forthbelow, specific weights in grams and identities of the ingredients areset forth for Examples 1-5.

                  TABLE IV                                                        ______________________________________                                        Example               Low Temp.                                                                             High Temp.                                                                             Chain                                  No.    MMA     MI     Initiator                                                                             Initiator                                                                              Regulator                              ______________________________________                                        1      490     10     0.3     0.1636   1.6558                                 2      480     20     0.3     0.1636   1.6558                                 3      470     30     0.3     0.1636   1.6558                                 4      460     40     0.3     0.1636   1.6558                                 5      450     50     0.3     0.1636   1.6558                                 ______________________________________                                    

The Table IV weights are the weights of the starting materials and allweights are in grams.

As shown in Table IV, both a secondary initiator, that is a hightemperature initiator with a 10 hours half life at greater than 100° C.and a mercaptan are used in the polymerization. The purpose of addingthe second initiator to the system is to drive the reaction to anextremely high conversion during the bulk polymerization.

Extremely high conversion percentage refers to the polymerization of thepresent invention which over 98% of the monomer ingredients areconverted to copolymer. In most conventional polymerization processesthe conversion rates are not as high because conventional processesusually have undesirable side reactions occurring and these reactionscause branching at high conversion. Through the use of chain transferagents, such as mercaptans, the bulk polymerization process of thepresent invention controls the branching and chain length so thatextremely high conversion rates are facilitated. One of the advantagesof the bulk polymerization, high conversion polymerization of thepresent invention is that extremely clear and clean copolymers maythereby be produced. In many conventional acrylic polymer processes theconversion is only up to about 50%, with the process then requiringunreacted monomer to be removed from the polymerization mixture andreturned to a reactor, with attendant contamination resulting during theseparation process. In the high conversion, bulk polymerization processof the present invention, separation of unreacted monomer is avoided andthe attendant contamination related thereto is thus also avoided.

Within the field of the present invention, contamination usually refersto particulate matter contained within the copolymer mixture and in thiscontext refers both to the size of the particles contained as well asthe number of particles. As discussed above, conventional polymerizationprocesses often produce relatively contaminated copolymers due to thetransferring of unreacted monomer back into a reaction vessel forfurther polymerization whereas the bulk polymerization process of thepresent invention avoids such a transfer. Additionally, the bulkpolymerization process of the present invention employs a 0.2 micronfilter to thus remove any particulate matter having a diameter equal toor greater than 0.2 microns and produce finished polymers free of largerparticles. Also, the bulk polymerization process of the presentinvention, as shown in FIG. 1, avoids prolonged contact with air and theattendant particulate impurities contained therein, through use ofclosed systems, vacuum purges, and the aforementioned filter.

It has been discovered that if the polymerization is carried outisothermally at approximately 60° C., the residual monomer content inthe polymer bulk cake is more than 20%, even after 15 hours of reaction.Experimental data indicate that after some conversion in the isothermalcondition, it is difficult to advance the reaction to completion becauseof the high viscosity of the copolymer system, which high viscosityinhibits the mobility of the unreacted monomers and polymer chainradicals. This phenomenon is usually explained by invoking a three-stepprocess model for free radical bulk polymerization. At first, theconversion, or propagation increases according to first-order kinetics,but then later the polymerization accelerates due to the slow diffusionof chain radicals. This secondary phenomenon is known as the Tromsdorffeffect. In other words, propagation increases but termination decreaseswhen conversion rate reaches approximately 80%. Thirdly, at even higherrates of conversion, i.e., extremely high conversion rates, that is,above 95%, there is a slowing down of the polymerization rate caused bythe relatively low concentration of monomers and a corresponding lowdiffusion rate of chain radicals that reduces the rate of propagation.In order to increase the polymerization rate to achieve extremely highconversion, i.e., greater than 95%, heat is supplied to the bulk mixturein a predetermined time and temperature sequence. The time-temperaturesequence is chosen so that viscosity is decreased, or maintainedrelatively low but not so low as to induce formation of bubbles in thebulk mixture. In a step-by-step increase of reaction temperature duringthis latter stage of polymerization, the slowing of the rate ofpropagation due to increase polymerization will be partially balanced bythe increasing temperature, but not to the extent existing in thepre-Tromsdorff condition. Also, by increasing the reaction temperatureand adding a secondary initiator, however, the conversion can be pushedto an extremely high conversion of greater than 80%. In the optimumpolymerization process of the present invention, the reaction isfinished after 6 hours at 135° C. in the fifth stage of polymerization.During this stage, that is, during the 6 hours at 135° C., the residualmonomers reach a minimum value of approximately 1%. Both the secondaryinitiator and the programmed time-temperature sequence promote themobility of the unreacted monomer and chain radicals so that it iscopolymerized even in a high viscosity environment.

The major purpose of adding the chain transfer agent in the bulkpolymerization system is to shorten the chain length of all of themacromolecules and to provide for a reasonably narrow molecular weightdistribution (MWD). Also, because radicals with smaller chain lengthsare not apt to become heavily entangled with neighboring molecules, themobility of the shorter radicals will not change as much as those of thelonger radicals. This relatively decreased mobility enhances uniformityof polymerization and is thus desireable in the present invention. Ithas been discovered that the addition of mercaptan(s) or amines, organicsulfur compounds such as carbon disulfide, carbon tetrachloride andother known chain transfer agents may be used. Mercaptans, however, arepreferred.

The copolymers of the present invention may be characterized in terms ofresidual monomer measurement, molecular weights, polydispersity, monomercomposition, and glass transition temperature.

1. Residual Monomer

The residual monomer present in the copolymers of the present invention,Examples 1-5, were determined by a gas chromatography (GC) method. Thepurpose of the determination of residual monomers was to make sure thatall of the polymers from the extremely high conversion polymerizationreaction were essentially free of monomer. A modified GC injector wasbuilt and used to determine the residual monomer content. The GCinjector is a conventional injector modified to include glass woolplaced inside of the injector liner as described in ["reference A"]. Theglass wool insert functions to block, or filter solid polymers from thesolution so that the liquid phase, i.e., the monomer, solvent, etc.,pass into the column. By using 3% ethyl methacrylate as the internalstandard calibration, both of the residual monomers could accurately bedetermined by this method.

Table V presents the results of residual monomer measurements forExamples 1-5, previously described. These data indicate that theExamples 1-5 copolymers of the present invention have been forced to anextremely high conversion. The low percent of residual monomerstypically do not have any significant influence on final physicalproperties in regard to the end use of the acrylic polymer. The residualmonomers in Examples 1-5 are shown in Table V below.

                  TABLE V                                                         ______________________________________                                        Residual Monomers of Examples 1-5 After                                       High Conversion Polymerization                                                       Residual     Residual  Total Residual                                  Example                                                                              MI (%)       MMA (%)   Monomer (%)                                     ______________________________________                                        1      0.15         0.60      0.75                                            2      0.42         0.57      0.99                                            3      0.79         0.53      1.21                                            4      1.03         0.49      1.52                                            5      1.48         0.42      1.90                                            ______________________________________                                    

2. Molecular Weights and Polydispersity

In the bulk polymerization process of the present invention themolecular weights of the copolymers can also be controlled or adjustedby the amount of chain transfer agents used. The chain transfer constantof each chain transfer agent, e.g., mercaptan, is a parameter to beconsidered when adjusting molecular weights of the final product and thedetermination of how much mercaptan to be used is in accordance withknown principles.

The molecular weights of Examples 1-5 were determined through the gelpermeation chromatography (GPC) and the results are set forth on TableVI. These data indicate that the molecular weights of all of Examples1-5 are relatively close to each other. Table VI also presents thepolydispersities of Examples 1-5 copolymers. Polydispersity refers tothe ratio of Mw to Mn, i.e., how broad is the molecular weightdistribution. For purposes of this invention Mw is defined as the weightaverage molecular weight and Mn is the number average molecular weight.

                  TABLE VI                                                        ______________________________________                                        Molecular Weights and Polydispersities of Examples 1-5                        Example  Mw          Mn      Polydispersity                                   ______________________________________                                        1        101,000     56,000  1.8                                              2        103,000     57,000  1.8                                              3        103,000     54,000  1.9                                              4        104,000     55,000  1.9                                              5        107,000     53,000  2.0                                              ______________________________________                                    

The operating conditions of the gel permeation chromatography unit areshown in Table VII. All of the measurements for molecular weight werecarried out at 23° C.; the polymer concentration was 0.005 g/ml andPerkin-Elmer software (GPC-5) was used for the calculation and dataanalysis. The universal calibration was based on polystyrene standards.The Table VII data is shown below.

                  TABLE VII                                                       ______________________________________                                        Operating Conditions for GPC Measurements                                     ______________________________________                                        A.     Apparatus                                                              1.     Perkin-Elmer series 10 LC pump                                         2.     Perkin-Elmer LC-25 RI detector                                         3.     Perkin-Elmer 3600 microcomputer                                        4.     Perkin-Elmer Chromatographic Interface                                 5.     Perkin-Elmer CHROM-2 software                                          6.     Perkin-Elmer GPC-5 software                                            B.     Testing Conditions                                                     1      Sample concentration - 0.005 g/ml                                      2.     Solvent - THF                                                          3.     Temperature: 23° C.                                             4.     Column combination: PL 10.sup.6 Å × 1, 10.sup.5 Å               × 1,                                                                    10.sup.4 Å × 1, 10.sup.3 Å × 1 and 10.sup.2               Å × 1                                                        5.     Flow rate - 1.0 ml/min                                                 6.     RI detector sensitivity - X10                                          7.     Injection volume - 80 μl                                            ______________________________________                                    

3. Monomer Composition

In order to confirm that the Examples 1-5 copolymers made by theextremely high conversion polymerization process of the presentinvention have the same ratio of monomers as the ratio in the initialingredient monomer mixture, a proton-NMR technique was used to determinethe monomer composition, or co-monomer ratio. In the proton-NMR spectraof MMA/MI copolymer the peak due to the --OCH₃ protons of MMA wasresolved from that due to the --NH proton of MI. The monomercompositions of the copolymers were calculated from the ratios of theareas under those peaks. The integral curves were measured and the areaswere taken to be proportional to the number of protons contributing tothe peak. Thus, the integral curve of --OCH₃ is proportional to 3 timesthe number of protons of MMA monomer in the chain and the integral curveassociated with the --NH proton is proportional to the number of protonsof MI monomer in the chain. By defining R as the molar ratio of MMAdivided by MI in the copolymer, then R equals the integral curve areaassociated with the --OCH₃ divided by three times the integral curvearea associated with the --NH protons.

These ratios were empirically obtained by averaging three determinationsof the appropriate integral curves and then using the above relationshipto provide the R values for the Example 1-5 copolymer composition asdescribed above. Table VIII presents these R values.

                  TABLE VIII                                                      ______________________________________                                        Monomer Composition Determined by .sup.1 H-NMR Method                                 MMA/MI          R                                                     Example (before polymerization)                                                                       (after polymerization)                                ______________________________________                                        1       49.0            48.9 ± 0.3                                         2       24.0            24.1 ± 0.2                                         3       15.7            15.7 ± 0.4                                         4       11.5            11.4 ± 0.3                                         5       9.0             8.8 ± 0.4                                          ______________________________________                                    

Proton-NMR spectra were obtained from a Bruker WM-500 spectrometerequipped with a 32-FT-100 pulse NMR computer system. The instrumentconditions used in obtaining the data were: 500 MHZ spectrum width, 10second acquisition time, 10 second delay time between pulse sequences,20 microsecond pulse widths, and a 45° flip angle. All samples weredissolved in CDCl₃ to give a concentration of 0.032 g/ml and thenanalyzed in 10 mm ID sample tubes.

4. Glass Transition Temperature Measurements

The glass transition temperatures of Examples 1-5 were measured by adifferential scanning calorimeter and are shown below in Table IX.

                  TABLE IX                                                        ______________________________________                                        Glass Transition Temperature                                                  Example  Glass Transition Temperature T.sub.g (°C.)                    ______________________________________                                        1        112                                                                  2        115                                                                  3        119                                                                  4        125                                                                  5        131                                                                  ______________________________________                                    

The glass transition temperature of all of the Examples 1-5 polymerswere determined using a Perkin-Elmer DSC-4 system equipped with amicroprocesser, interface and TADS software. Each sample weight wasabout 30 mg and a 5° C./min heating rate and a 10 psi helium gasenvironment were used.

In regard to Table IX it is known that pure MMA has a glass transitiontemperature of about 105°-110° C., which is significantly lower than theglass transition temperatures of the copolymers of the presentinvention. Also, a different product which has been recently advertisedbut not commercially available, known as Kamax™ made by Rohm & HaasCompany, has a stated glass transition temperature of 143°-160° C.

Also, it is known that polycarbonates have relatively high glasstransition temperatures; however, their cost is relatively high andtheir weatherability is relatively poor in comparison to bothconventional acrylic polymers and to the acrylic copolymers of thepresent invention.

EXAMPLE 6

Another copolymer of the present invention, Example 6 was prepared insufficient quantity to be tested for various physical properties.

The Example 6 copolymer was made from the following ingredient mixture:

    ______________________________________                                        Ingredient          Amount (gram) (ml)                                        ______________________________________                                        MMA                 1260       g                                              N-methylmaleimide   140        g                                              Lauryl peroxide     1.12       g                                              2,5-dimethyl-2,5-di-                                                                              1.575      g                                              (t-butylperoxy) hexane                                                        n-dodecyl mercaptan 4.634      g                                              Tinuvin-P ™ from Ciba-Geigy                                                                    0.56       g                                              Stearyl alcohol internal lubricant                                                                5.95       g                                              Indigo toner        0.455      ml                                             ______________________________________                                    

The ingredient mixture was prepared as described above and with atemperature-time sequence as follows:

    ______________________________________                                        Temperature   Time                                                            ______________________________________                                         63° C.                                                                              To the 8th hour                                                  75° C.                                                                              3 hours                                                         115° C.                                                                              4 hours                                                         135° C.                                                                              6 hours                                                         ______________________________________                                    

The Tinuvin-P™ was added to improve UV protection because it is a knownUV radiation absorber. Also, Indigo toner is a known blue toner added tomodify the color characteristics of the finished product.

A number of samples of the Example 6 copolymer were made and tested inaccordance with test method ASTM D-638 at 0.20 inches/minute and at roomtemperature. The following Table X presents the test data on maximumload, tensile strength, modulus and elongation.

All samples were 0.502 inches in width. Samples 1 and 4 were 0.127inches in length whereas samples 2, 3 and 5 were 0.128 inches in length.

                  TABLE X                                                         ______________________________________                                        Example 6                                                                            Maximum   Tensile                                                      Sample Load      Strength   Modulus Elongation                                No.    (Lbs.)    (Psi)      PSI × E5                                                                        Percent                                   ______________________________________                                        1      505       7,920      5.23    1.8                                       2      343       5,340      5.22    1.2                                       3      448       6,970      4.63    1.7                                       4      581       9,110      4.72    2.6                                              484       7,530      4.77    1.8                                              Average:  7,370      4.91    1.8                                       ______________________________________                                    

Similarly, flexural strength and modulus of the Example 6 copolymer weredetermined in accordance with ASTM D-790-84a, at 0.2 inches/minute, witha span length of 2.00 inches and at room temperature. The results areset forth in Table XI. For this test the sample lengths were 0.131 inchfor sample 1, 0.132 inch for sample 2 and 0.132 inch for sample 3. Allthree samples were 0.500 inches in width

                  TABLE XI                                                        ______________________________________                                               Maximum              Flexural                                          Sample Load      Type of    Strength                                                                             Modulus                                    No.    Pounds    Failure    PSI    PSI × ES                             ______________________________________                                        1      37.1      5% strain  13,000 5.58                                       2      43.9      5% strain  15,100 5.61                                       3      48.7      5% strain  16,800 5.54                                                        Average:   15,000 5.58                                       ______________________________________                                    

Two samples of the Example 6 copolymer were also tested for compressivestrength and modulus in accordance with ASTM D-648, using a heating rateof 2.0+1-0.2° C., an immersion medium of DC200 silicone oil and a spanof 4.0 inches. Sample 1 had a width of 0.499 inch and sample 2 had awidth of 0.500 inch. Both samples were 0.131 inches in length. Table XIIpresents the resulting test data.

                  TABLE XII                                                       ______________________________________                                              Calculated Actual      Fiber  Deflection                                Sample                                                                              Applied Load                                                                             Applied Load                                                                              Stress Temp                                      No.   Grams      Grams       PSI    Degree F.                                 ______________________________________                                        1     1.435      651         461    244                                       2     1.441      654         464    246                                                                    Average:                                                                             245                                       ______________________________________                                    

Three additional copolymers prepared in accordance with the presentinvention have employed N-phenylmaleimide (Example 7), N-methylmaleimide(Example 8) and N-ethylmaleimide (Example 9) as the group II monomer.The ingredients for these three examples are set forth below in TableXIII.

                  TABLE XIII                                                      ______________________________________                                                              Group II                                                                      Maleimide Weight                                        Example No.                                                                             MMA Weight  (grams)                                                 ______________________________________                                        7         90 g        10 g    N-phenymaleimide                                8         90 g        10 g    N-methylmaleimide                               9         90 g        10 g    N-ethylmaleimide                                ______________________________________                                    

Each of the Examples 7-9 ingredient mix also contained 0.06 g laurylperoxide, 0.33 g 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 0.331 gn-dodecyl mercaptan, 0.027 g Tinuvin-P™, 0.417 g stearyl alcohol, and0.013 g indigo toner. The Examples 8-9 finished polymers were clear andthe Example 7 polymer was yellow. All three of the Examples 7-9copolymers were prepared with a temperature-time polymerization sequenceof:

63° C. to the 8th hour, then

55° C. to the 13th hour, then

75° C. for the 3 hours, then

115° C. for 2 hours, and then

135° C. for 4 hours.

The Example 7 copolymer had a Tg of 121° C., the Example 7 copolymer hada Tg of 121° C. and the Example 8 copolymer had a Tg of 122° C.

EXAMPLES 10-14

Several additional example copolymers were prepared usingN-cyclohexylmaleimide as the group II maleimide. The ingredientmixtures, polymerization cycles and relevant physical data are set forthbelow.

    ______________________________________                                        Example 10                                                                    Ingredient      Amount (grams) (ml)                                           ______________________________________                                        MMA             300       g        75%                                        N-cyclohexylmaleimide                                                                         100       g        25%                                        Lauryl peroxide 0.32      g                                                   2,5-dimethyl-2,5-di-                                                                          0.50      g                                                   (t-butylperoxy) hexane                                                        N-dodecyl mercaptan                                                                           1.2       g                                                   Tinuvin-P ™  0.16      g                                                   Stearyl alcohol 1.70      g                                                   Indigo toner    0.2       ml                                                  ______________________________________                                    

The polymerization cycle used was:

63° C. to the 8th hour, then

75° C. for 3 hours, then

115° C. for 4 hours, and then

135° C. for 6 hours.

The measured onset Tg was 132.5° C.

    ______________________________________                                        Example 11                                                                    Ingredient        Weight (gram)                                               ______________________________________                                        MMA               300     g       75%                                         N-cyclohexylmaleimide                                                                           100     g       25%                                         Lauryl peroxide   0.32    g                                                   2,5-dimethyl-2,5-di-                                                                            0.45    g                                                   (t-butylperoxy) hexane                                                        N-dodecyl mercaptan                                                                             1.2     g                                                   Tinuvin-P ™    0.16    g                                                   Stearyl alcohol   1.70    g                                                   ______________________________________                                    

The polymerization cycle used was:

63° C. to the 8th hour, then

75° C. for 3 hours, then

115° C. for 4 hours, and then

135° C. for 6 hours.

The onset Tg was 132° C. and the mid-point Tg was 135° C. The M₂=95,834, M_(n) =45,778 and P_(d) =2.093.

    ______________________________________                                        Example 12                                                                    Ingredient        Weight (gram)                                               ______________________________________                                        MMA               320     g       80%                                         N-cyclohexylmaleimide                                                                           80      g       20%                                         Lauryl peroxide   0.32    g                                                   2,5-dimethyl-2,5-di-                                                          (t-butylperoxy) hexane                                                                          0.45    g                                                   N-dodecyl mercaptan                                                                             1.324   g                                                   Tinuvin-P ™    0.16    g                                                   Stearyl alcohol   1.70    g                                                   ______________________________________                                    

The measured onset TG=120.6° C.

    ______________________________________                                        Example 13                                                                    Ingredient        Weight (gram)                                               ______________________________________                                        MMA               340     g       85%                                         N-cyclohexylmaleimide                                                                           60      g       15%                                         Lauryl peroxide   0.32    g                                                   2,5-dimethyl-2,5-di-                                                                            0.45    g                                                   (t-butylperoxy) hexane                                                        N-dodecyl mercaptan                                                                             1.324   g                                                   Tinuvin-P ™    0.16    g                                                   Stearyl alcohol   1.70    g                                                   ______________________________________                                    

The measured onset Tg=124.7° C.

The polymerization cycle used for both Examples 12 and 13 was:

63° C. to the 8th hour, then

75° C. for 3 hours, then

115° C. for 4 hours, and then

125° C. for 4 hours.

    ______________________________________                                        Example 14                                                                    Ingredient        Weight (gram)                                               ______________________________________                                        MMA               360     g       90%                                         N-cyclohexylmaleimide                                                                           40      g       10%                                         Lauryl peroxide   0.32    g                                                   2,5-dimethyl-2,5-di-                                                                            0.45    g                                                   (t-butylperoxy) hexane                                                        N-dodecyl mercaptan                                                                             1.324   g                                                   Tinuvin-P ™    0.16    g                                                   Stearyl alcohol   1.70    g                                                   ______________________________________                                    

The polymerization cycle used was:

63° C. to the 8th hour, then

75° C. for 3 hours, then

115° C. for 4 hours, and then

135° C. for 6 hours.

The measured onset Tg=122.95° C. and the sample was slightly yellow.

From the Examples 10-14 data it appears that the Example 10 formulationis preferable, in light of the relatively high Tg. It is also noted thatalthough MMA/MI is the preferred copolymer, in terms of clarity, thelack of availability of MI in commercially competitive quantities andprices at present will limit its commercial uses. On the other hand,N-cyclohexylmaleimide is available at commercially useful prices andquantities and is thus an acceptable compound of the present invention,even though it lacks the clarity of the preferred maleimide copolymer.

EXAMPLES 15-17

Three additional laboratory scale samples of copolymers of the presentinvention were prepared to illustrate Group I, II, III and Group II, IIIcopolymers as referred to previously. These three copolymers were madefrom ingredient mixtures as follows:

    ______________________________________                                        Ingredient          Amount (grams) (ml)                                       ______________________________________                                        Example 15                                                                    MMA                 288        g                                              Ethyl acrylate      12         g                                              N-cyclohexylmaleimide                                                                             100        g                                              Lauryl peroxide     0.32       g                                              2,5-dimethyl-2,5-di-                                                                              0.45       g                                              (t-butylperoxy) hexane                                                        N-dodecyl mercaptan 1.2        g                                              Tinuvin-P ™ from Ciba-Geigy                                                                    0.16       g                                              Stearyl alcohol internal lubricant                                                                1.70       g                                              Indigo toner        0.3        ml                                             Example 16                                                                    Ethyl acrylate      150        g                                              N-cyclohexylmaleimide                                                                             20         g                                              Lauryl peroxide     0.14       g                                              2,5-dimethyl-2,5-di-                                                                              0.18       g                                              (t-butylperoxy) hexane                                                        N-dodecyl mercaptan 0.48       g                                              Indigo toner        0.12       ml                                             Example 17                                                                    MMA                 130        g                                              Ethyl acrylate      5          g                                              Maleimide           12         g                                              Lauryl peroxide     0.12       g                                              2,5-dimethyl-2,5-di-                                                                              0.16       g                                              (t-butylperoxy) hexane                                                        N-dodecyl mercaptan 0.45       g                                              Tinubin-P ™ from Ciba-Geigy                                                                    0.06       g                                              Stearyl alcohol internal lubricant                                                                0.0638     g                                              ______________________________________                                    

The polymerization cycle for each of Examples 15-17 was as follows: Thepolymerization cycle used was:

63° C. to the 8th hour, then

55° C. for 3 hours, then

75° C. for 3 hours, then

115° C. for 4 hours, and then

135° C. for 6 hours.

The Example 15 copolymer was yellow and had an onset Tg of 126° C. TheExample 16 copolymer was slightly yellow and had a Tg of 129° C. TheExample 17 copolymer was clear and had a Tg of 120 ° C.

EXAMPLE 18

A production scale copolymer of the present invention was also made withthe following ingredient mixture:

    ______________________________________                                        Ingredient           Amount                                                   ______________________________________                                        MMA                  75        lbs.                                           N-cyclohexylmaleimide                                                                              25        lbs.                                           Lauryl peroxide      (0.08     lbs.)                                          2,5-dimethyl-2,5-di- (0.125    lbs.)                                          (t-butylperoxy) hexane                                                        N-dodecyl mercaptan  0.3       lbs.                                           Tinuvin-P ™ from Ciba-Geigy                                                                     0.04      lbs.                                           Stearyl alcohol      0.425     lbs.                                           Indigo toner         15        ml                                             ______________________________________                                    

The copolymer was yellow and had an onset Tg of 130° C., witn a midpointTg of 135° C. The M_(n) was 45,000, the M_(w) was 95,000 and the P_(d)was 2.1. The copolymer had a specific gravity of 1.194.

It is believed that the high conversion free radical bulk polymerizationof methacrylates, acrylates and maleimides of the present invention canprovide a new generation of acrylic plastics to obtain a superior,clear, high temperature heat resistant acrylic copolymers.

Because the copolymers of the present invention are prepared by a bulkpolymerization process as described, they do not contain residualemulsifiers, solvents or dispersion agents as would copolymers producedby other polymerization techniques. These impurities operate to lowerTg's and to degrade the clarity of the resulting copolymers. Thus, thecopolymers of the present invention are substantially emulsifer free,solvent free and dispersion agent free. They also exhibit extremely goodclarity, absences of particulate and have higher Tg's than identicalcopolymers produced by other methods. Also the bulk polymerizationprocess of the present invention is generally less costly thanconventional extrusion technology.

The above-described preferred embodiments and samples are provided byway of illustration only and are not intended to limit the invention toonly those samples as specifically set forth above. Rather, it isanticipated that numerous alternative formulations ofmethacrylate/acrylate/maleimide compositions may be formulated withinthe principles of the present invention and numerous equivalentcompositions may be formulated within the scope of the presentinvention, which is defined according to the claims appended hereto.

I claim:
 1. A method of making a bulk methacrylate-maleimide copolymer comprising the steps of:selecting a first monomer from the group methyl methacrylate, ethyl methacrylate, ethyl acrylate, butyl acrylate and propyl acrylate; selecting a second monomer from the group maleimide, N-methylmaleimide, N-ethylmaleimide, N-phenylmaleimide and N-cyclohexylmaleimide; selecting a low temperature initiator having a half life of about ten hours at about 50-70° C.; selecting a high temperature initiator having a half life of about ten hours at about 90-130° C.; selecting a chain transfer agent means for controlling chain lengths of copolymers to be formed from said first and second monomer; thoroughly mixing the first monomer, second monomer, low temperature initiator, high temperature initiator and chain transfer agent means in a container to form a mixture; purging the mixture with a relatively non-reactive gas to form a purged mixture; passing the purged mixture through a filter to form a filtered mixture; placing a predetermined quantity of the filtered mixture into a cell to form a mixture bulk; placing the mixture bulk into a reaction chamber; heating the reaction chamber to a first temperature of about 55°-70° C. and maintaining the first temperature for about 5-10 hours; establishing in the reaction chamber a second temperature of about 40°-55° C. and maintaining the second temperature for about 5-10 hours; establishing in the reaction chamber a third temperature of about 70°-85° C. and maintaining the third temperature for about 5-10 hours; establishing in the reaction chamber a fourth temperature of about 100°-120° C. and maintaining the fourth temperature for at least 3 hours; and establishing in the reaction chamber a fifth temperature of about 120°-250° C. and maintaining the fifth temperature for at least 3 hours to form a bulk copolymer.
 2. The method of claim 1 further comprising the steps of:selecting a third monomer from the group ethyl acrylate, butyl acrylate and propyl acrylate prior to mixing and including the third monomer in the mixing step.
 3. The method of either claim 1 or 2 wherein the first monomer is methyl methacrylate and the second monomer is maleimide. 